Method for assembling a dual inner flexible insulated pouch

ABSTRACT

This is a method for assembling a dual inner flexible insulated pouch. A flat sheet of heat-sealable film is folded in such a manner as to form a dual inner pouch with two pocket openings at a bottom side and a pouch opening at a top side. The film is sealed by heat to form a permanent dual inner pouch structure containing two pockets each having an opening at the bottom side. One panel of flexible insulation material is inserted into each of the openings of the two pockets of the dual inner pouch at the bottom side. The bottom side of the pouch is placed into a bag formed of film so that the open ends of the pockets at the bottom side of the pouch are at a bottom closed end of the bag formed of film. The bag formed of film is heated so that it is sealed to the dual inner pouch.

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This is a Divisional Application and Applicant is claiming thebenefit of the pending prior filed Nonprovisional application Ser. No.09/800,945 filed on Mar. 7, 2001 which claims the benefit of ProvisionalApplication No. 60/189,794 filed Mar. 16, 2000.

FIELD OF THE INVENTION

[0002] This invention relates generally to portable containers fortemperature sensitive products and more particularly to a flexibleinsulated pouch used in shipping refrigerated and frozen pharmaceuticaland food products. The apparatus provides temporary storage that allowsrefrigerated and frozen pharmaceutical and food products to betransported without spoilage.

[0003] Portable containers for temperature sensitive products have beencommercially available for many years. One type of container availableis a rigid, molded foam walled portable container. Because this type ofcontainer is constructed from Expanded Polystyrene and other resins itis prone to damage from impact during transportation and storage.Another disadvantage is that the container is rigid and does not allowfor convenient storage and shipping due to space considerations.

[0004] Another type of portable container is a flexible portablecontainer. Because the container is flexible it allows for convenientstorage and shipping. However these flexible containers aredisadvantaged by incorporating vacuum packed open celled foam panelsthat require the operator using the container to puncture each panelprior to shipment to release the vacuum seal. Consequently, the abilityof such flexible containers to provide adequate insulation duringtransportation and temporary storage of refrigerated and frozenpharmaceutical and food products is directly related to the successfulpuncturing of these vacuum packed opened celled foam panels. Therefore,it is desirable to have a flexible portable container that does notrequire the operator to puncture the vacuum packed foam panels.

[0005] The present invention provides a protective, flexible, insulatedstructure for transportation and temporary storage of refrigerated andfrozen pharmaceutical and food products without spoilage and withouthaving to puncture vacuum packed foam panels. This is done by making apouch that has multiple plies of closed cell polypropylene foam and apolypropylene film on the inside of the pouch that is enclosed in a filmbag.

BACKGROUND OF THE INVENTION

[0006] There are various needs for portable containers for temperaturesensitive products. Some of these needs include storage and shipping offood and pharmaceutical products. The present technology for shippingcontrolled temperature products is rigid foam coolers with refrigerantgel packs, bricks or sheets.

[0007] The rigid foam coolers provide adequate insulation forrefrigeration however they don't provide an efficient means fortransportation. The rigid foam is constructed from expanded polystyreneand other resins. This type of foam is crushable and prone to damagefrom impact during the transportation process. Additionally, because ofthe rigid design, it is not practical in transportation because of spaceconsiderations.

[0008] Because the rigid foam coolers were inefficient in thetransportation process flexible portable containers are being used.

[0009] One example of a flexible portable container is described in U.S.Pat. No. 4,620,633, Protective Envelope Device for Packaging FragileArticles issued Nov. 4, 1986 to Lookholder. This device was originallydesigned for cushioning but it has been adapted to the insulatedshipping application due to a product void in the market. It has anouter wall and an inner wall with a mass of compressed resilientopen-celled cellular material enclosed in the space between the walls.In order for this device to work properly the operator is required topuncture the open celled foam panels prior to shipment to release thevacuum seal. The ability of this device to provide adequate insulationis directly related to the successful puncturing of the vacuum packedopen celled foam panels. The success of this device is therefore subjectto human error.

[0010] There is no known apparatus that provides an efficient means fortransporting and temporary storage of refrigerated and frozenpharmaceutical and food products without the need for an operator tocorrectly puncture open celled foam panels. The present invention solvesthe problem by providing a flexible insulated pouch for transportationand temporary storage of refrigerated and frozen pharmaceutical and foodproducts without spoilage thereof without the need to puncture thevacuum packed foam panels as described in U.S. Pat. No. 4,620,633.

BRIEF SUMMARY OF THE INVENTION

[0011] The present invention provides a method for assembling a dualinner flexible insulated pouch. The apparatus has a pouch havingmultiple plies of closed cell polypropylene foam. A film bag made ofmaterial which acts as a moisture and oxygen barrier surrounds thepouch. A heat seal on the film bag joins the film bag to one side of thepouch. The present invention also provides for a flexible insulatedpouch wherein the inside of the pouch can have a film on the inside. Thefilm may be made of polypropylene or other material.

[0012] The present invention also provides for a method for assembling adual inner flexible insulated pouch where the film bag is comprised of apolymer extrusion that is cooled into a sheet form of varying thickness.

[0013] The present invention also provides for a method for assembling adual inner flexible insulated pouch that has a pouch that is a dualinner pouch that encapsulates two flexible panels of multiple plies offlexible insulated material. The multiple plies of flexible insulatedmaterial can be closed cell, flexible polypropylene foam or otherflexible insulation material.

[0014] I provide a method to assemble the insulated foam pouch with adual inner pouch by folding a flat sheet of heat-sealable film laminatein such a manner as to form a pouch with two pocket openings at a bottomside. The pouch is then heat sealed to form a permanent dual inner pouchstructure containing two pockets with two openings at the bottom side.One flexible panel is placed into each pocket opening of the dual innerpouch. The dual inner pouch is then placed into the film bag so that theopen end of the bottom side of the dual inner pouch is at a bottomclosed end of the film bag. The film bag is heated by induction so thatit is sealed to the dual inner pouch.

A BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 Isometric view of the flexible insulated pouch;

[0016]FIG. 2 Side sectional view of the flexible insulated pouch;

[0017]FIG. 3 Isometric view of the flexible insulated pouchincorporating dual inner pouch and semi-rigid panels;

[0018]FIG. 4 Side sectional view of the flexible insulated pouchincorporating dual inner pouch;

[0019]FIG. 5A side view in elevation of the dual inner pouch method ofassembly;

[0020]FIG. 6A side view in elevation of the insertion of dual innerpouch into the film bag;

[0021]FIG. 7A sectional view of the induction heat seal process bondingthe dual inner pouch;

[0022]FIG. 8 Sectional view of the induction heat seal process bondingthe film bag and the foam pouch.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT Definitions

[0023] 1. Portable: An item that by virtue of its weight and/or exteriordimensions can be transported by a person without mechanical assistance.

[0024] 2. Temperature Sensitive Products: Perishable products that mustbe maintained within a specified temperature range to avoid spoilage.

[0025] 3. Insulated: With relation to a shipping container, the abilityto minimize heat transfer during shipment and storage outside of acontrolled temperature environment.

[0026] Heat Transfer is discussed in more detail below:

[0027] Heat can be transferred by three primary mechanisms:

[0028] 1. Radiation

[0029] 2. Convection

[0030] 3. Conduction

[0031] Radiation is transmitted as electromagnetic waves, which causeheating, as they are absorbed. Convection heat transfer is caused by airmovement across a surface of a material.

[0032] Conduction heat transfer is governed by the density and thicknessof the insulating material. All materials conduct heat at differentrates. This rate of conduction is referred to as the K value for a givenmaterial.

K=BTU×Inches

[0033] Hrs.×ft²×F°

[0034] Where, BTU=British Thermal Unit

[0035] Or, the amount of heat that passes through one square foot, 1inch thick, of material in one hour for every degree temperaturedifference between both sides of the material. The more common term inrelating to insulation is the R factor, which is a measure of theinsulating quality of a material. $R = \frac{1}{K}$

[0036] To keep a product cool a container that has a low “K” valueshould be selected. Similarly, high “R” values offer better insulation.

[0037] 4. Flexible: Pliable, Not rigid.

[0038] 5. Pouch: A flexible shipping and storage container manufacturedfrom a poly, paper, or composite structure. Typically, one side of thepouch has an opening to allow for insertion and removal of the productand the other three sides are closed. Pouches can be flat or they canhave gussets on one or more sides to provide additional interior storagevolume.

[0039] 6. Closed Cell: A cellular structure that provides for pockets oftrapped air. Not open celled.

[0040] 7. Polypropylene: A specific resin type used in the formulationof films and foams. Polypropylene is characterized by specific meltingtemperatures, barrier properties and other distinct physical properties.

[0041] 8. Refrigerated: Temperature range from 33° F. to 50° F.

[0042] 9. Frozen: Temperature below 32° F.

[0043] 10. Rigid: Not pliable, not flexible.

[0044] 11. Molded: Products that are formed using a combination of maleand female dies, heat, and pressure.

[0045] 12. Vacuum Packed: A manufacturing process that extracts oxygenand other gases from a closed environment.

[0046] 13. Foam: Plastic foam material consists of a gas phase dispersedin a solid plastic phase and derives its properties from both. The solidplastic component forms the matrix. The gas phase is contained in voidsor cells and is often referred to as the blowing or foaming agent.

[0047] 14. Film: Polymer extrusion that is cooled into a sheet form ofvarying thicknesses

[0048] 15. Multiple Plies: Individual layers of material substantiallythinner in gauge than the overall gauge of the finished sheet. Eachlayer is attached to the other layer with heat and pressure to form afinished sheet.

[0049] 16. Polypropylene Foam: A plastic foam material utilizingpropylene resin as the solid plastic component.

[0050] 17. Closed Cell Polypropylene Foam: A closed cell foam whereineach cell (more or less spherical in shape) is completely enclosed by athin wall or membrane of plastic. See definition no. 16 forpolypropylene foam.

[0051] 18. Polypropylene Film: A plastic film material utilizingpropylene resin as the solid plastic component.

[0052] 19. Moisture Vapor Barrier (MVTR): The moisture permeability of astructure. The formula for measurement of a Moisture Barrier is outlinedbelow:

MVTR=Grams H20/100 Sq. In,/24 Hrs

[0053]  The higher the MVTR measurement, the greater the amount ofmoisture vapor that can pass through 100 sq. in. of the structure in 24hrs.

[0054] 20. Oxygen Barrier (OTR): The oxygen permeability of a structure.

OTR=Cubic Centimeters O²/100 Sq. In./24 Hrs

[0055]  The higher the OTR measurement, the greater the amount of oxygenthat can pass through 100 sq. in. of the structure in 24 hours.

[0056] 21. Induction Heating: A mechanical device that conducts heat.When used in the assembly process of the invention, the inductionheating is in the form of a “jaw” which lightly compresses finished filmon exterior of both the flexible insulated pouch and the dual poach andthrough the application of heat bonds the foam pouch to the film bag.

DESCRIPTION

[0057]FIG. 1 shows a flexible insulated pouch 2. The flexible insulatedpouch 2 is comprised of a foam pouch 4 having multiple plies of closedcell polypropylene foam. Surrounding the pouch 4 is a film bag 6. Thefilm bag 6 is made of material that acts as a moisture vapor barrier andan oxygen barrier. A heat seal 8 joins the pouch 4 to the film bag 6.The pouch 4 can have a film 10 on the inside.

[0058]FIG. 2 shows a side section view of a flexible insulated pouch 2,a film bag 6, and a pouch 4. The film bag 12 is comprised of a polymerextrusion that is cooled into a sheet form of varying structure. Thepolymer extrusion can be a laminated film structure or a non-laminatedfilm structure. If the film bag 6 is comprised of a laminated filmstructure, one laminate 12 is comprised of a linear low-densitypolyethylene or low-density polypropylene (preferable 1.0-4.0 milthickness). The second laminate 14 is comprised of metallized ornon-metallized polyester (preferable 48-60 gauge thickness. If thislaminate is metallized it will be coated with an additional 4-12 micronthickness metallizing.) The two laminates 12 and 14 are extruded to forma finished film. If the film bag 6 is comprised of a non-laminated filmstructure, the entire film bag 6 would be comprised of an extruded sheetof linear low density polyethylene, low density polypropylene or otherlow or high density resin. The pouch 4 may have a film 10 on the inside.The film 10 may be comprised of polypropylene.

[0059]FIG. 3 shows a flexible insulated pouch 2 comprised of a film bag6 surrounding a dual inner pouch 16. The dual inner pouch 16 containstwo flexible panels 18 and 20, one on each side of the dual inner pouch16. The two flexible panels 18 and 20 are comprised of flexibleinsulation material.

[0060]FIG. 4 shows a sectional view of a flexible insulated pouch 2 witha dual inner pouch 16. A laminated film bag 6 is depicted but anon-laminated film bag 6 may be used as described in FIG. 2. Onelaminate 12 and a second laminate 14 comprise the film bag 6. The dualinner pouch 16 is encapsulating two flexible panels 18 and 20 one oneach side of the flexible insulated pouch 2. The two flexible panels 18and 20 are comprised of multiple plies of closed cell, flexiblepolypropylene foam or other flexible insulation material. Preferably theflexible panels 18 and 20 are comprised of multiple plies of closedcell, flexible polypropylene (⅛-2 inch thickness).

[0061]FIG. 5. shows the assembly of a dual inner pouch 16. The dualinner pouch 16 is comprised of a heat-sealable film. A flat sheet of theheat-sealable film is folded and heat sealed in such a manner as to formtwo pocket openings 22 and 24 each at the bottom side 26 of the dualinner pouch 16 and a dual insulated pouch opening 28 at the top side 30of the dual inner pouch 16. The flexible panels 18 and 20 are die cut orsheeted to a rectangular panel of predetermined length and width. Theflexible panels 18 and 20 are then inserted into the two pocket openings22 and 24 at the bottom side 26 of the pouch dual inner pouch 16.

[0062]FIG. 6. shows the dual inner pouch 16 being inserted into the filmbag 6 with the bottom side 26 of the dual inner pouch 16 at the closedend 34 of the film bag 6. The film bag 6 is sealed to the dual innerpouch 16 by induction heating 32 shown in FIG. 7.

[0063]FIG. 7. is a side sectional view of the flexible insulated pouch 2with a dual inner pouch 16 surrounded by a film bag 6. A heat sealingdevice 32 is used to join the dual inner pouch 16 to the film bag 6.

[0064]FIG. 8 is a side sectional view of the flexible insulated pouch 2with a pouch 4 surrounded by a film bag 6. A heat sealing device 32 isused to join the pouch 4 to the film bag 6.

[0065] As various changes could be made in the above construction andmethod without departing from the scope of the invention, it is intendedthat all matter contained in the above description as shown in theaccompanying drawings shall be interpreted as illustrative and not as alimitation.

I claim:
 1. A method for assembling a dual inner flexible insulatedpouch comprising: (a) folding a flat sheet of heat-sealable film in sucha manner as to form a dual inner pouch with two pocket openings at abottom side and a pouch opening at a top side; (b) sealing the film withheat to form a permanent dual inner pouch structure containing twopockets each having an opening at the bottom side; (c) inserting onepanel of flexible insulation material into each of the openings of thetwo pockets of the dual inner pouch at the bottom side; (d) placing thebottom side of the pouch into a bag formed of film so that the open endsof the pockets at the bottom side of the pouch are at a bottom closedend of the bag formed of film; and (e) heating by induction the bagformed of film so that it is sealed to the dual inner pouch.
 2. A methodfor assembling a dual inner flexible insulated pouch as recited in claim1 wherein the panel of flexible insulation material comprises multipleplies of closed cell flexible polypropylene foam.